Multistage Variable Impactor

ABSTRACT

An inertial gas-liquid separator and method is provided, including variable orifice jet nozzle structure having a variable orifice area dependent upon axial movement of a plunger relative to a housing sleeve, and in another embodiment having first and second flow branches, with the first flow branch being continuously open, and the second flow branch having a variable flow controller controlling flow therethrough.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 11/168,688, filed Jun. 28, 2005, and a continuation-in-part ofU.S. patent application Ser. No. 10/946,603, filed Sep. 21, 2004. The'688 application is a continuation-in-part of the '603 application.

BACKGROUND AND SUMMARY

The above noted parent applications related to inertial gas-liquidimpactor separators for removing and coalescing liquid particles from agas-liquid stream, including in engine crankcase ventilation separationapplications, including closed crankcase ventilation (CCV) and opencrankcase ventilation (OCV).

Inertial gas-liquid separators are known in the prior art. Liquidparticles are removed from a gas-liquid stream by accelerating thestream or aerosol to high velocities through nozzles or orifices anddirecting same against an impactor, typically causing a sharpdirectional change, effecting the noted liquid separation. Such inertialimpactors have various uses, including in oil separation applicationsfor blowby gases from the crankcase of an internal combustion engine.

The present invention arose during continuing development effortsrelating to the above noted parent inventions.

In one embodiment, a system is provided for separating oil from blowbygas of an internal combustion engine, including providing increasedseparation efficiency early in the life of the engine without sufferingobjectionably high pressure drop late in the life of the engineincluding end-of-life condition of the engine. As an engine wears, moreblowby gas is created and the impactor in the inertial gas-liquidseparator sees a larger flow and increased pressure from the crankcase.When this happens, the impactor actually begins to perform with higherefficiency, but also has a larger pressure drop. Standard impactors mustbe designed to meet this end-of-life condition in order not to producetoo high of a pressure drop. This means the efficiency early in the lifeof the engine may not be optimized.

In one embodiment, multiple stages allow the impactor design to beoptimized for several points in the life of the engine. For example, inone embodiment, the blowby gas is exposed to fewer nozzles in thebeginning when pressure and flow are lower. As pressure increases, morestages are opened. This means that efficiency can be high from thebeginning of life, and pressure drop is controlled as the engine wears.This embodiment provides improved performance by delivering a moreconsistent efficiency and pressure drop over the life of the engine. Inone embodiment, the device has one impactor stage that is constantlyopen to blowby gas flow, and one or more stages that are opened withrelief valves as pressure increases. In one preferred embodiment, onlythe constant stage impactor is open at the beginning-of-life of theengine, and all stages will be open by the end-of-life of the engine.

In another embodiment, an inertial gas-liquid separator is provided withvariable orifice jet nozzle structure having a variable orifice areadependent upon axial movement of a plunger relative to a housing sleeve.The variable orifice jet nozzle structure may be used with or withoutthe noted constantly open impactor stage of the above embodiment.

BRIEF DESCRIPTION OF THE DRAWINGS Parent Applications

FIGS. 1-22 are taken from the noted parent '603 application. FIGS. 23-26are taken from the noted patent '688 application.

FIG. 1 is a schematic sectional illustration of an inertial gas-liquidimpactor separator in accordance with the parent '603 application.

FIG. 2 is a sectional view taken along line 2-2 of FIG. 1.

FIG. 3 is a schematic perspective view of a portion of FIG. 1 butshowing another embodiment.

FIG. 4 is a schematic perspective view of a portion of FIG. 1 butshowing another embodiment.

FIG. 5 is a perspective elevational view of an inertial gas-liquidimpactor separator incorporating the embodiment of FIG. 4.

FIG. 6 is a perspective view partially broken away of the constructionof FIG. 5.

FIG. 7 is a perspective view partially broken away of the constructionof FIG. 5.

FIG. 8 is an exploded perspective view of a portion of FIG. 5.

FIG. 9 is a sectional view of the construction of FIG. 5 showing a firstposition of the actuator.

FIG. 10 is like FIG. 9 and shows another position of the actuator.

FIG. 11 is a schematic perspective view of a portion of FIG. 1 butshowing another embodiment.

FIG. 12 is a schematic illustration of a portion of another inertialgas-liquid impactor separator in accordance with the parent '603application.

FIG. 13 is a sectional view of an inertial gas-liquid impactor separatorincorporating the embodiment of FIG. 12.

FIG. 14 is like FIG. 13 and shows another position of the actuator.

FIG. 15 is a sectional view of the construction of FIG. 13.

FIG. 16 is a perspective view of the construction of FIG. 13.

FIG. 17 is an exploded perspective view of the construction of FIG. 16.

FIG. 18 is another exploded perspective view of the construction of FIG.16.

FIG. 19 is a schematic perspective view of a portion of another inertialgas-liquid impactor separator in accordance with the parent '603application.

FIG. 20 is a sectional view of another embodiment of an inertialgas-liquid impactor separator in accordance with the parent '603application.

FIG. 21 is a top elevation view taken along line 21-21 of FIG. 20.

FIG. 22 is an enlarged view of a portion of FIG. 20.

FIG. 23 is a schematic sectional view of an inertial gas-liquidseparator in accordance with the parent '688 application.

FIG. 24 is like FIG. 23 and shows another embodiment.

FIG. 25 is like FIG. 23 and shows another embodiment.

FIG. 26 is like FIG. 23 and shows another embodiment.

Present Application

FIG. 27 is schematic sectional illustration of an inertial gas-liquidimpactor separator in accordance with the invention.

FIG. 28 is like FIG. 27 and shows a further operational condition.

FIG. 29 is an enlarged view of a portion of FIG. 27.

FIG. 30 is a sectional view taken along line 30-30 of FIG. 29.

FIG. 31 is a perspective view from below of the construction of FIG. 29.

FIG. 32 is a schematic sectional illustration of another embodiment ofan inertial gas-liquid impactor separator.

FIG. 33 is like FIG. 32 and shows a further embodiment.

FIG. 34 is like FIG. 32 and shows a further embodiment.

FIG. 35 is an end elevation view of the device of FIG. 34.

FIG. 36 is a perspective view of a component of FIG. 32.

FIG. 37 is like FIG. 32 and shows a further embodiment.

DETAILED DESCRIPTION Parent Applications

The following description of FIGS. 1-26 is taken from the above notedparent '603 and '688 applications.

FIG. 1 shows an inertial gas-liquid impactor separator 30 for coalescingand removing liquid particles from a gas-liquid stream 32, shown in anexemplary crankcase ventilation separation application for an internalcombustion engine 34. In such application, it is desired to vent blow-bygases from crankcase 36 of engine 34. Untreated, these gases containparticulate matter in the form of oil mist and soot. It is desirable tocontrol the concentration of the contaminants, especially if the blow-bygases are to be recirculated back to the engine's air intake system, forexample at air intake manifold 38. The oil mist droplets are generallyless than 5μ in diameter, and hence are difficult to remove usingconventional fibrous filter media while at the same time maintaining lowflow resistance as the media collects and becomes saturated with oil andcontaminants.

Separator 30 includes a housing 40 having an inlet 42 for receivinggas-liquid stream 32 from engine crankcase 36, an outlet 44 fordischarging a gas stream 46 to air intake manifold 38, and a drain 45draining separated fluid at 47 from impactor collector 54 and returningcollected oil droplets at 47 to crankcase 36. Nozzle structure 48 in thehousing has a plurality of nozzles provided by orifices such as 50, 52,FIGS. 1, 2, receiving the gas-liquid stream at 58 from inlet 42 andaccelerating the gas-liquid stream through nozzles 50, 52. The pluralityof nozzles provides a cumulative flow in parallel therethrough. Aninertial impactor collector 54 in the housing is in the path of theaccelerated gas-liquid stream at 58 and causes liquid particleseparation by a sharp directional change as shown at 56. In thepreferred embodiment, impactor collector 54 has a rough porouscollection or impingement surface 60 causing liquid particle separationfrom the gas-liquid stream, and is like that shown in U.S. Pat. No.6,290,738, incorporated herein by reference. Nozzle orifices 50, 52 mayhave a venturi or frustoconical shape as in the incorporated '738patent.

A variable flow actuator 62 varies the cumulative flow through theplurality of nozzles in response to a given parameter. In one desirableembodiment, cumulative flow velocity is varied, though other flowcharacteristics may be varied. The gas-liquid stream flows axially alongan axial flow direction at 58 through orifices 50, 52. Actuator 62 ismovable along a given direction relative to the orifices to vary thenoted cumulative flow. In one embodiment, actuator 62 is moveable alongthe noted given direction relative to the orifices to vary the totalarea and hence the resultant flow velocity. In FIGS. 1, 2, actuator 62is a disk or plate movable across one or more of the orifices to changethe cross-sectional area thereof transverse to axial flow direction 58.Disk 62 is movable as shown at arrow 64 left-right in FIGS. 1, 2,transversely to axial flow direction 58. In the embodiment of FIGS. 1,2, disk 62 as a plurality of elongated slots or openings 66, 68 alignedwith respective nozzle orifices 50, 52 and transversely slidabletherealong to vary the size thereof available to axial flowtherethrough, and hence to vary the cumulative flow area. In a furtherembodiment, one or more of nozzle orifices 50, 52 may be closed oropened during movement of disk 62, to thus vary the number of orificesavailable to axial flow therethrough, to thus vary the noted cumulativeflow area. In a further embodiment, movement of actuator disk 62 variesboth the size and number of the orifices, for example movement ofactuator disk 62 back and forth along direction 64 may expand andrestrict the orifices along a cross-sectional area thereof transverse toflow direction 58, to vary the size of the orifices, and movement ofactuator disk 62 back and forth along direction 64 may open and closeother of the orifices, to vary the number of orifices through which thegas-liquid stream flows.

In one embodiment, the noted parameter to which variable flow actuator62 responds is pressure of the gas-liquid stream. Housing 40 includes apressure sensor 70 in the form of a diaphragm or membrane coupledthrough link 72 to actuator 62 to actuate the latter to move left-rightat 64 in FIGS. 1, 2. As the pressure of the gas-liquid stream increases,diaphragm 70 moves leftwardly in FIG. 1, which in preferred formincreases the size of orifices 50, 52, etc. (increases thecross-sectional flow area thereof) and/or increases the number oforifices 50, 52, etc. open to flow therethrough. The increasing pressureof the gas-liquid flow stream in housing chamber 74 overcomes the biasspring 76 to cause leftward movement of diaphragm 70. If the gas-liquidflow pressure decreases, then biasing spring 76 moves actuator disk 62rightwardly in FIG. 1, preferably to reduce the size and/or number oforifices 50, 52, etc. In this manner, a desired pressure differential ΔP(delta P) is maintained, eliminating the need to make compromisesbetween minimum and maximum flow rates, engine sizes, changingconditions such as engine wear, speed, braking, etc. The variable flowactuator maximizes efficiency by adapting to different engine sizes,flow ratings, and changing conditions during engine operation, andovercomes prior trade-offs required in a fixed flow separator. In theembodiment of FIG. 1, housing chamber 78 on the opposite side ofdiaphragm 70 from chamber 74 is vented to atmosphere as at vent openings80, 82, for referencing ΔP, though other reference pressures may beused.

FIG. 3 shows a further embodiment having an actuator plate or disk 84translationally slidable left-right as shown at arrow 86 along housing88 to vary the size of nozzle orifices such as 90, 92, as elongatedslots or openings 94, 96 of disk 84 moved therealong. Slots or openings94, 96 may have a frustoconical taper 98 to enhance the noted venturiacceleration effect. As disk 84 moves leftwardly in FIG. 3, the size ofventuri orifices 90, 92 increases, i.e. leftward movement of actuatordisk 84 expands the size of orifices 90, 92 along a cross-sectional areathereof transverse to axial flow direction 58, to vary the size of theorifices. Rightward movement of actuator disk 84 restricts orifices 90,92 along the cross-sectional area thereof transverse to axial flowdirection 58. Alternatively, or additionally, leftward movement ofactuator disk 84 may open additional orifices, and rightward movement ofactuator disk 84 may close some orifices, to vary the number of orificesthrough which the gas-liquid stream flows.

FIG. 4 shows another embodiment having an actuator disk 100 rotatableabout a rotation axis 102 parallel to axial flow direction 58. Actuatordisk 100 is rotatable clockwise as shown at arrow 104 about axis 102 torestrict and/or close one or more nozzle orifices 106, 108, etc., ofhousing wall 110, as slots 112, 114 in actuator disk 100 slidetransversely thereacross.

FIGS. 5-10 show a preferred implementation of the embodiment of FIG. 4.Housing 120 has an inlet 122, comparable to inlet 42, FIG. 1, forreceiving the gas-liquid stream 32, e.g. from crankcase 36. Housing 120has an outlet 124, comparable to outlet 44, FIG. 1, for discharging gasstream 46, e.g. to air intake manifold 38. Housing 120 has a drain 126,comparable to drain 45, FIG. 1, draining separated fluid 47 fromimpactor collector 54, e.g. returning collected oil droplets at 47 tocrankcase 36. Actuator disk 100 is rotationally mounted to housingspindle 128 to rotate about axis 102. Disk 100 is connected by link 130to diaphragm plate 132 having legs 134 extending through diaphragm 136and mounted on the opposite side to spring plate 138, such thatdiaphragm 136 is sandwiched between plates 132 and 138. Biasing spring140 bears between spring plate 138 and closure cap 142 mounted to thehousing and sealed thereto at perimeter 144 and providing a firstchamber 146 on one side of the diaphragm, and a second chamber 148 onthe other side of the diaphragm.

FIG. 9 shows a low pressure condition of the gas-liquid flow stream 32,with actuator disk 100 rotated clockwise as shown at arrow 150 to afirst position minimizing cumulative flow through the plurality ofnozzle orifices 106, 108, etc., for example restricting the size of oneor more such orifices and/or closing one or more of such orifices. FIG.10 shows a higher pressure condition of gas-liquid flow stream 32, withactuator disk 100 rotated counterclockwise as shown at arrow 152 to asecond position maximizing cumulative flow through the plurality ofnozzle orifices 106, 108, etc., e.g. by expanding one or more of suchorifices and/or opening one or more of such orifices. The actuator has aplurality of positions between its minimum and maximum cumulative flowpositions in response to pressure of the gas-liquid stream to maintainthe pressure constant, i.e. maintain a constant ΔP relative to a givenreference. The given reference may be atmospheric pressure, for exampleas provided by one or more vent openings 154, 156 in end cap 142communicating with chamber 148.

In the embodiment of FIGS. 5-10, the noted pressure sensor is providedby diaphragm 136 having first and second opposite sides 158 and 160,with the first side 158 coupled through plate 132 and link 130 toactuator disk 100, comparably to diaphragm 70, FIG. 1, having first andsecond opposite sides 69 and 71, with first side 69 coupled through link72 to actuator disk 62. One of the first and second sides of thediaphragm is exposed to pressure in the gas-liquid stream 32 to controlmovement of the actuator. In FIGS. 1 and 9, the noted first side 69, 158of the respective diaphragm 70, 136 is exposed to pressure in thegas-liquid stream to control movement of the actuator. In otherembodiments, to be described, the second side of the diaphragm isexposed to pressure in the gas-liquid stream to control movement of theactuator. In FIGS. 1-2 and 5-10, the biasing member 76, 140 is overcomeby a given pressure in gas-liquid stream 32 in respective chamber 74,146 on respective first side 69, 158 of respective diaphragm 70, 136.

FIG. 11 shows another embodiment having an actuator disk 161 rotatableabout rotation axis 102 parallel to axial flow direction 58. Actuatordisk 161 is rotationally mounted on housing plate 162 at spindle 163 andis rotational to open or close one or more nozzle orifices such as 164,165, etc. Upon rotation of disk 161 as shown at arrow 166, one or moreradial arms 167, 168 of the disk, which may have differing arcuatelengths, open or close respective nozzle orifices, to thus vary thenoted cumulative flow through the nozzle structure by varying the numberof nozzle orifices available for flow therethrough.

FIG. 12 shows another embodiment having an actuator disk 170translational along a direction parallel to axial flow direction 58.Actuator 170 is movable from solid line position 172 to dashed lineposition 174 along arrow 176 in the same direction as axial flowdirection 58 to decrease the noted cumulative flow of the gas-liquidstream by restricting or closing nozzle orifices such 178 in housingwall 180. Actuator 170 is movable from dashed line position 174 to solidline position 172 as shown at arrow 182 in the opposite direction toaxial flow direction 58, to increase the noted cumulative flow. Theactuator includes valve stems such as 184 having respective conicallyshaped valve heads such as 186 engageable with respective valve seatsprovided by the nozzle orifices such as 178. The valve head 186 isconically shaped along a taper which narrows toward a direction pointingin the same direction as axial flow direction 58. The valve seats may beconically shaped complementally to the valve heads. In an open valvecondition as shown in solid line at 172, the gas-liquid stream flows asshown at 188, 190 through nozzle orifice 178 and strikes impactionsurface 60, which may be the facing surface of actuator 170 or may beprovided by an impactor collector such as 54 mounted thereto, causingliquid particle separation as above.

FIGS. 13-18 show a preferred implementation of the embodiment of FIG.12. Housing 200 has an inlet 202, comparable to inlet 42, FIG. 1, forreceiving the gas-liquid stream 32, e.g. from crankcase 36. Housing 200has an outlet 204, comparable to outlet 44, FIG. 1, for discharging gasstream 46, e.g. to air intake manifold 38. Housing 200 has a drain 206,comparable to drain 45, FIG. 1, draining separated fluid 47 fromimpactor collector 54, e.g. returning collected oil droplets at 47 tocrankcase 36. Inner housing wall 180 has a plurality of nozzle orifices178, 208, etc. Actuator disk 170 has a plurality of valve stems 184,210, etc. having respective valve heads 186, 212, etc. opening andclosing and/or restricting and expanding respective nozzle orifices 178,208, etc. Actuator disk 170 is mounted on diaphragm 214 which is sealedat its periphery 216 in the housing. The housing includes a chamber 218receiving the gas-liquid stream from inlet 202, a subchamber 220 betweeninner housing wall 180 and first side 222 of diaphragm 214, and achamber 224 on the second side 226 of the diaphragm. The housing isclosed by a first closure cap 228 enclosing chamber 218, and a secondclosure cap 230 enclosing chamber 224.

The gas-liquid stream 32 flows through housing inlet 202 into chamber218 between closure cap 228 and inner housing wall 180. Subchamber 220is between inner housing wall 180 and diaphragm 214 and receives thegas-liquid flow stream communicated through nozzle orifices 178, 208,etc., when open. Chamber 224 is between closure cap 230 and the notedsecond side 226 of diaphragm 214 and includes a spacer ring 232 having aplurality of spacer legs 234 for providing a plenum in chamber 224. Aplurality of communication passages 236, 238, etc. provide communicationof gas-liquid flow stream pressure therethrough as shown at arrows 240,242, etc. from chamber 218 into chamber 224 as shown at arrows 244, 246,etc. The size and number of communication passages 236, 238, etc. areselected such that the ratio of pressure on second side 226 of diaphragm214 resulting from and relative to the pressure of the gas-liquid streamis greater than the ratio of the pressure on first side 222 of diaphragm214 relative to and resulting from the pressure of the gas-liquidstream. Diaphragm 214 is inherently biased, or alternatively has anon-stretched position, as shown in FIG. 13, with nozzle orifices 178,208, etc. closed by valve heads 186, 212, etc., which is the dashed lineposition 174 shown in FIG. 12. This inherent bias or non-stretchedposition of the diaphragm has a bias toward such closed position of thenozzle orifices which is greater than the pressure in chamber 224 onsecond side 226 of the diaphragm, e.g. at low engine speed. As thepressure of the gas-liquid stream increases, the pressure in chamber 224on second side 226 of the diaphragm increases and overcomes the inherentbias of diaphragm 214 to stretch and move the diaphragm to the positionshown in FIG. 14, which is the solid line position 172 in FIG. 12, tobegin to open nozzle orifices 178, 208, by moving valve heads 186, 212,etc. away from their respective valve seats along direction 182, FIG.12. This opening movement of the valves is opposed and counterbalancedby the pressure in subchamber 220 on first side 222 of the diaphragm nowavailable due to the gas-liquid stream flow as shown at arrows 188, 190through the respective nozzle orifices into subchamber 220. The notedratio of pressures on the first and second sides of the diaphragmcontrol the opening and closing of the valves, and vary the size of thenozzle orifices, and if desired the number of orifices opened or closed.

The cumulative flow through the nozzles is varied by variable flowactuator 170 wherein movement of such actuator varies at least one ofthe size and number of orifices 178, 208, etc. The cumulative flow mayfurther be varied by varying: the axial height of valve stems 184, 210,etc. stem-to-stem; the taper, width, etc. of valve heads 186, 212, etc.from head-to-head; the size of the orifices 178, 208, etc.; the pressureratio on opposite sides 222 and 226 of the diaphragm by varying the sizeand number of communication passages 236, 238; and various combinationsthereof.

Actuator 170 has a first position as shown in FIG. 13 and in dashed line174 in FIG. 12, minimizing or closingly stopping cumulative flow of thegas-liquid stream through the plurality of nozzle orifices 178, 208. Theactuator has a second position as shown in FIG. 14 and in solid line 172in FIG. 12, maximizing cumulative flow through the plurality of nozzleorifices 178, 208, etc. Actuator 170 is moved by the pressure sensorprovided by diaphragm 214 between the noted first and second positionsand a plurality of positions therebetween in response to pressure of thegas-liquid stream to maintain such pressure constant, i.e. maintain aconstant ΔP if desired. As above, this overcomes prior trade-offs in afixed separator which is non-adaptive to changing engine or flowconditions nor different engine sizes. Side 226 of the diaphragm isexposed to pressure in the gas-liquid stream in both of the noted firstand second positions of the actuator and the intermediate positionstherebetween. Side 222 of the diaphragm is exposed to pressure in thegas-liquid stream in the noted second position and intermediatepositions of the actuator.

FIG. 19 shows a further embodiment, with an actuator 250 translationalalong a direction 252 parallel to axial flow direction 58, comparably toactuator 170, FIG. 12, for opening and closing, and/or enlarging andrestricting nozzle orifices such as 254, 256, etc. in housing wall 258.Actuator 250 has a plurality of valve stems 260, 262, etc. havingconically shaped valve heads 264, 266, etc., engageable with respectivevalve seats such as 268, 270, etc. which valve seats may be conicallyshaped complementally to the valve heads. Unlike FIG. 12, valve heads264, 266 in FIG. 19 are conically shaped along a taper which narrowstoward a direction pointing opposite to axial flow direction 58.Variable flow actuator 250 varies the cumulative flow of the gas-liquidflow stream through nozzle orifices 254, 256, etc. in response to agiven parameter, by moving back and forth as shown at arrow 252. Ifpressure in the gas-liquid flow stream is the designated parameter, thepressure against valve heads 264, 266 may be used to open the valves,and the pressure against such valve heads and surface 272 of theactuator disk may be used to vary and expand the cumulative flow area byincreasing the cross-sectional area of the nozzle orifices. A biasingspring such as 76, 140 may bear against surface 274 of the actuator diskto bias the actuator to a closed or restricted position. Actuator 250moves in the same direction as axial flow direction 58 to increase thenoted cumulative flow, and moves in the opposite direction to axial flowdirection 58 to decrease the noted cumulative flow.

FIGS. 20-22 show a further embodiment having a plurality of actuatorassemblies 280, 282, 284, 286 in housing 290. In actuator assembly 280,housing sub-wall 292 has a plurality of nozzle orifices such as 294,296, 298, etc. through which the gas-liquid flow stream at 58 isaccelerated and strikes inertial impactor collector 54 at impactionsurface 60, as above, causing liquid particle separation from thegas-liquid stream. Impactor collector 54 is mounted on variable flowactuator 300, or alternatively face surface 302 of the actuator mayprovide the impaction surface 60. Actuator 300 is translational back andforth as shown at arrow 304 along a direction parallel to axial flowdirection 58, and is biased to a closed position (upwardly in FIG. 22),by a spring 306 bearing between underside 308 of actuator disk 300 and aspring seat 310 of the housing. In the upwardly biased closed positionshown in FIG. 22, an annular gasket 312 on the outer circumference ofactuator disk 300 engages the lower apex of V-shaped valve seat 314 ofthe housing in sealing relation to block gas stream and liquid streamflow therepast. Actuator 300 is movable in a second direction(downwardly in FIG. 22) to a second open position wherein gasket 312 ismoved downwardly away from and disengaged from valve seat 314 by a gaptherebetween to permit gas stream flow therepast to the housing outlet,shown schematically at 44 in FIG. 22, and to permit liquid stream flowtherepast to the housing drain, shown schematically at 45 in FIG. 22.The remaining actuator assemblies 282, 284, 286 are the same.

The inertial impactor collector of the above embodiments of FIGS. 1-19is provided in FIGS. 20-22 as a plurality of impaction surfaces 60, 60a, 60 b, 60 c each receiving the gas-liquid stream through a respectiveset of one or more orifices 294, 296, 298, etc. The variable flowactuator is provided by a plurality of impaction buttons 300, 300 a, 300b, 300 c each carrying a respective impaction surface 60, 60 a, 60 b, 60c. Each impaction button is movable between the noted closed and openpositions independently of the other impaction buttons. The notedcumulative flow of the gas-liquid stream at 58 is varied by varying thenumber of impaction buttons in at least one of the closed and openpositions. For example, cumulative flow may be increased by opening oneor more of the impaction buttons, and decreased by closing one or moreimpaction buttons. The impaction buttons are spring biased at differentspring rates, to provide differential sequential opening and closingthereof. For example, each of springs 306, 306 a, 306 b, 306 c has adifferent spring rate, such that, for example, impaction button 300opens first in response to increasing pressure, and then impactionbutton 300 a opens in response to further increasing pressure, and thenimpaction button 300 b opens in response to yet further increasingpressure, and so on. Impaction buttons 300, 300 a, 300 b, 300 c aretranslational along a direction parallel to axial flow direction 58, andare biased to the noted closed position (upwardly in FIG. 20) along thenoted direction parallel to axial flow direction 58.

Referring to FIG. 1, gas-liquid stream 32 becomes gas stream 46 andflows from upstream to downstream through the housing from inlet 42 thenthrough nozzle orifices 50, 52, etc. then to inertial impactor collector54 at impaction surface 60 then to outlet 44. In the embodiments ofFIGS. 1-19, the noted actuator is upstream of the inertial impactorcollector. In the embodiment of FIGS. 20-22, the actuator is downstreamof the inertial impactor collector.

FIG. 23 shows an inertial gas-liquid separator 320 for removing liquidparticles from a gas-liquid stream. A housing 322 has an inlet 324 forreceiving a gas-liquid stream 326, and an outlet 328 for discharging agas stream 330. Nozzle structure 332 in the housing includes a pluralityof nozzles such as 334 receiving the gas-liquid stream from inlet 324and accelerating the gas-liquid stream through the nozzles. An inertialimpactor collector 336 is provided in the housing in the path of theaccelerated gas-liquid stream and causes liquid particle separation fromthe gas-liquid stream, followed by flow of the gas stream as shown at338, and drainage of liquid 340 at drain 342. A variable flow actuator344 is movable, e.g. up and down in FIG. 23, to open and close avariable number of nozzles 334.

Variable flow actuator 344 is responsive to pressure of gas-liquidstream 326. The variable flow actuator responds to increasing pressureby moving, e.g. upwardly in FIG. 23, to open more of nozzles 334. Thevariable flow actuator responds to decreasing pressure to close more ofnozzles 334, e.g. by moving downwardly in FIG. 23. In this manner, asubstantially constant pressure drop is maintained across inertialgas-liquid separator 320 between inlet 324 and outlet 328notwithstanding changing flow conditions of the gas-liquid streamtherethrough. It is preferred that the distance between nozzles 334 andinertial compactor collector 336 be constant and unchanged by movementof variable flow actuator 344.

In FIG. 23, variable flow actuator 344 is provided by a piston 346axially slidable along a cylinder 348 extending along an axis 350. Thecylinder has cylinder wall 352 with a plurality of apertures 354therethrough providing the noted plurality of nozzles. The apertures arecovered and uncovered by piston 346 during sliding of the piston alongthe cylinder to respectively close and open the nozzles. Inertialimpactor 336 is an annular member spaced radially outwardly of cylinder348 by an annular acceleration gap 356 therebetween. Apertures 354extend radially through cylinder wall 352. Gas-liquid stream 326 flowsaxially within cylinder 348 and then radially outwardly throughapertures 354 uncovered by piston 346 and is accelerated into annularacceleration gap 356 and impact inertial impactor collector 336 causingliquid particle separation from the gas-liquid stream. Gas-liquid stream326 flows in a given axial direction within cylinder 348, e.g. upwardlyin FIG. 23. After the noted separation, the gas stream at 338 flows inthe same given axial direction along the exterior of cylinder 348. Thegas-liquid stream flows through inlet 324 in the noted given axialdirection. The gas stream at 330 flows through outlet 328 in the samenoted given axial direction.

Piston 346 has a leading surface 358 facing the incoming flow of thegas-liquid stream 326 thereagainst. Leading surface 358 is configured todirectionally guide and direct flow to apertures 354 in cylinder wall352. In one embodiment, such directional configuration is a cone shapeor a convex shape or a channeled guide surface, etc.

In the embodiment of FIG. 23, piston 346 is a gravimetric piston relyingon the weight of the piston to regulate flow. The noted axis of movementis vertical. Piston 346 has the noted bottom face 358 facing downwardlyand receiving the incoming flow of the gas-liquid stream 326thereagainst. Piston 346 slides upwardly in cylinder 348 in response toincreasing pressure of the gas-liquid stream 326 to open up more ofapertures 354. The piston slides downwardly in the cylinder in responseto decreasing pressure of the gas-liquid stream 326 to close off more ofapertures 354. The top of the cylinder includes a vent hole 360 to avoidcreation of a vacuum within the cylinder during piston movement, so asnot to impede movement of the piston.

FIG. 24 shows another embodiment and uses like reference numerals fromabove where appropriate to facilitate understanding. A biasing member,such as spring 362, biases piston 346 a against the incoming flow ofgas-liquid stream 326 thereagainst. Piston 346 a slides in a first axialdirection, e.g. upwardly in FIG. 24, against the bias of biasing spring362 in response to increasing pressure of gas-liquid stream 326 to openmore of apertures 354. Piston 346 a slides in a second oppositedirection, e.g. downwardly in FIG. 24, as biased by biasing spring 362in response to decreasing pressure of gas-liquid stream 326 to close offmore of apertures 354.

FIG. 25 shows another embodiment of an inertial gas-liquid separator 370for removing liquid particles from a gas-liquid stream. A housing 372has an inlet 374 for receiving a gas-liquid stream 376, and has anoutlet 378 for discharging a gas stream 380. Nozzle structure 382 in thehousing has a plurality of nozzles 384 receiving the gas-liquid streamfrom inlet 374 and accelerating the gas-liquid stream through thenozzles. An inertial impactor collector 386 is provided in the housing,which may be an interior wall of the housing, in the path of theaccelerated gas-liquid stream. A variable flow actuator 388 in thehousing is movable to open and close a variable number of nozzles 384.

Housing 372 has a wall 390 facing inertial impactor collector 386 andseparated therefrom by an annular acceleration gap 392 therebetween.Wall 390 has a plurality of apertures 394 therethrough providing thenoted nozzles 384. Variable flow actuator 388 is provided by a rollingdiaphragm 396 having a resilient flexible region 398 covering anduncovering apertures 394 in a flexing motion to respectively close andopen nozzles 384. Diaphragm 396 has a first side 400 communicating withinlet 374 and exposed to the incoming flow of the gas-liquid stream 376.The diaphragm has a second opposite side 402 communicating with outlet378. First side 400 of the diaphragm has a changing effective area,which effective area is defined as the area exposed to incoming flow.The effective area of the diaphragm increases in response to increasingpressure of gas-liquid stream 376, and the diaphragm uncovers and opensup more of apertures 394. The effective area of the diaphragm decreasesin response to decreasing pressure of gas-liquid stream 376, and thediaphragm covers and closes off more of apertures 394. Wall 390 is acylindrical wall of a cylinder 404 in the housing and extending axiallyalong axis 406. Apertures 394 extend radially through cylinder wall 390.Diaphragm 396 has an outer portion 408 extending axially along theinterior of cylinder wall 390 and is flexible radially away therefrom touncover and open more of the apertures 394. Diaphragm 400 has a centralportion 410 spanning radially inwardly from the outer portion andmovable in a first axial direction, e.g. downwardly in FIG. 25, to flexouter portion 408 of the diaphragm radially inwardly away from apertures394 and out of engagement of cylinder wall 390 to uncover and open moreof the apertures. Central portion 410 is movable in a second oppositeaxial direction, e.g. upwardly in FIG. 25, to flex outer portion 408 ofthe diaphragm radially outwardly toward apertures 394 and intoengagement with cylinder wall 390 to cover and close off more of theapertures 394. Biasing spring 412 biases central portion 410 of thediaphragm in the noted second axial direction, e.g. upwardly in FIG. 25,and against the incoming flow of gas-liquid stream 376. The separatedliquid drains as shown at arrow 414 at drain 416. The gas stream flowsas shown at arrows 418 to outlet 378. A central column 420 supports anupper sleeve 422 in telescopic axial sliding relation which in turnsupports upper central portion 410 of the diaphragm. The base of supportcolumn 420 has a plurality of slots or apertures 424 passing the gasflow therethrough to outlet 378.

FIG. 26 shows another embodiment of an inertial gas-liquid separator 430for removing liquid particles from a gas-liquid stream. Housing 432 hasan inlet 434 for receiving a gas-liquid stream 436, and has an outlet438 for discharging a gas stream 440. Nozzle structure 442 in thehousing has a plurality of nozzles 444 receiving the gas-liquid streamfrom inlet 434 and accelerating the gas-liquid stream through nozzles444. An inertial impactor collector 446 is provided in the housing inthe path of the accelerated gas-liquid stream and causes liquid particleseparation from the gas-liquid stream. The liquid drains as shown atarrow 448 at drain 450. The gas stream continues as shown at arrows 452,454 to outlet 438. A variable flow actuator 456 is movable to open andclose a variable number of nozzles 444. The housing has a wall 458facing inertial impactor collector 446 and separated therefrom by anacceleration gap 460 therebetween. Wall 458 has a plurality of apertures462 therethrough providing the noted nozzles. Variable flow actuator 456is provided by a rolling diaphragm 464 having a resilient flexibleregion 466 covering and uncovering apertures 462 in a flexing motion torespectively close and open the nozzles. Diaphragm 464 has a first side468 communicating with inlet 434 and exposed to the incoming flow ofgas-liquid stream 436. The diaphragm has a second opposite side 470communicating with outlet 438. First side 468 of the diaphragm has achanging effective area, such effective area being defined as the areaexposed to incoming flow. The effective area of the diaphragm increasesin response to increasing pressure of gas-liquid stream 436, and thediaphragm uncovers and opens more of apertures 462. The effective areaof the diaphragm decreases in response to decreasing pressure ofgas-liquid stream 436, and the diaphragm covers and closes off more ofapertures 462.

Wall 458 is a plate having an incoming flow opening 472 therethroughcommunicating with inlet 434 and receiving the incoming flow ofgas-liquid stream 436. The incoming flow flows axially along axis 474through opening 472. Plate 458 extends laterally outwardly from opening472. The plurality of apertures 462 extend axially through plate 458 andare laterally outward of opening 472. Diaphragm 464 has an outer portion476 extending laterally along plate 458 and flexible axially, e.g.upwardly in FIG. 26, away therefrom to uncover and open up more ofapertures 462. Diaphragm 464 has a central portion 478 spanninglaterally inwardly from the outer portion and movable in a first axialdirection, e.g. upwardly in FIG. 26, to flex outer portion 476 of thediaphragm axially away from apertures 462 and out of engagement of plate458 to uncover and open up more of apertures 462. Central portion 478 ofthe diaphragm is movable in a second opposite axial direction, e.g.downwardly in FIG. 26, to flex outer portion 476 of the diaphragmaxially toward apertures 462 and into engagement with plate 458 to coverand close off more of apertures 462. A biasing spring 480 biases centralportion 478 of the diaphragm in the noted second axial direction, e.g.downwardly in FIG. 26, and against the incoming flow of gas-liquidstream 436. The gas-liquid stream 436 flows through opening 472 in thenoted first axial direction, e.g. upwardly in FIG. 26, and then flows asshown at arrows 482 in the noted second axial direction, e.g. downwardlyin FIG. 26. The gas stream flows from acceleration gap 460 as shown atarrows 452, 454 to outlet 440 in the noted first axial direction.

In the above noted embodiments, the system automatically adapts thenumber or size of apertures to the flow, to keep restriction as constantas possible. This is desirable, particularly in internal combustionengine applications in a truck in a braking mode. In other applications,a change in hole or aperture area is done step by step at extendedintervals, for example manually at service intervals for the vehicle,particularly when crankcase pressure reaches a predetermined level. Inone example, piston 346, FIG. 23, can be manually changed betweendifferent positions at service intervals and retained by a retainer suchas a detent, latch, finger in slot, or the like, in a fixed axialposition until the next further service interval, at which the servicetechnician will determine if the piston should be moved to a differentaxial position to cover or uncover more or less apertures 354 until thenext service interval, and so on. In another example, the disks such as84 of FIG. 3 or 100 of FIG. 4 may be fixed in place at a serviceinterval and remain so fixed until the next service interval, at whichtime they may be adjusted and moved by the service technician, andremain so adjusted until a subsequent service interval, and so on. Inanother example, a pair of disks may be provided which can be angularlyrotated or slid relative to each other and locked in position, with aseries of detents or clicks, with gradations indicating to the servicetechnician a given setting corresponding to a given crankcase pressurereading. The mechanic will then manually slide or rotate a disk or othervariable actuator to a given set position, to accommodate wear since thelast service interval and to correspond to a current crankcase pressurereading as the engine ages.

Present Application

FIG. 27 shows an inertial gas-liquid separator 510 for removing liquidparticles from a gas-liquid stream 512, for example oil particles from ablowby gas stream from crankcase 514 of internal combustion engine 516.In such embodiment, the separator returns separated oil 518 at drain 520to crankcase 514, and returns separated air 522 at outlet 524 to airintake manifold 526 of the engine. In such application, it is desired tovent blowby gases from crankcase 514 of engine 516. Untreated, thesegases contain particulate matter in the form of oil mist and soot. It isdesirable to control the concentration of the contaminants, especiallyif the blowby gases are to be recirculated back to the engine's airintake system, for example at air intake manifold 526. The oil mistdroplets are generally less than 5 μm in diameter, and hence aredifficult to remove using conventional fibrous filter media while at thesame time maintaining low flow resistance as the media collects andbecomes saturated with oil and contaminants. The separator may be usedin closed crankcase ventilation (CCV) systems and in open crankcaseventilation (OCV) systems, as well as other inertial gas-liquid impactorseparator applications.

Separator 510 includes a housing 528 having an inlet 530 for receivinggas-liquid stream 512, and an outlet 524 for discharging a gas stream522. The inlet may have a gasket such as O-ring 532 for sealed mountingto a component such as an engine crankcase. First and second flowbranches 534 and 536, FIGS. 27, 28, are provided through the housingfrom inlet 530 to outlet 524. First flow branch 534 has a set of one ormore nozzles 538 receiving gas-liquid stream 512 from inlet 530 andaccelerating the gas-liquid stream in the first flow branch in adownstream direction through the first set of one or more nozzles 538against a first inertial impactor collector 540 in the housing in thepath of the accelerated gas-liquid stream through first flow branch 534and causing liquid particle separation. Inertial impactor collector 540in the housing is in the path of the accelerated gas-liquid stream andcauses liquid particle separation by a sharp directional change as shownat 542. In the preferred embodiment, impactor collector 540 has a roughporous collection or impingement surface causing liquid particleseparation from the gas-liquid stream, and is like that shown in U.S.Pat. No. 6,290,738, incorporated herein by reference. In anotherembodiment, a smooth impervious impingement surface is used, providing asharp cut-off size particle separation, as noted in the '738 patent.Nozzles 538 may be provided by orifices having a venturi orfrustoconical shape as in the incorporated '738 patent. Second flowbranch 536 has a second set of one or more nozzles 544 receiving thegas-liquid stream from inlet 530 and accelerating the gas-liquid streamin second flow branch 536 in a downstream direction through the secondset of one or more nozzles 544 and against a second inertial impactorcollector 546 in the housing in the path of the accelerated gas-liquidstream through second flow branch 536 and causing liquid particleseparation by a sharp directional change as shown at 548, FIG. 28. Avariable controller 550 in second branch 536 controls flow therethrough.

Variable controller 550, FIGS. 29-31, in second flow branch 536, FIGS.27, 28, is responsive to pressure of gas-liquid stream 512. Variablecontroller 550 in second flow branch 536 is upstream of the noted secondset of one or more nozzles 544. First and second flow branches 530 and536 preferably diverge at a junction 552 downstream of inlet 530, andvariable flow controller 550 is preferably downstream of such junction552. First flow branch 534 is continuously open such that gas-liquidstream 512 can continuously flow therethrough and through the first setof one or more nozzles 538. Variable flow controller 550 includes avalve 554, to be described, actuatable to control flow through secondflow branch 536 and the second set of one or more nozzles 544. Valve 554is preferably a pressure relief valve responsive to increasing pressureof gas-liquid stream 512. Valve 554 may be actuatable between open andclosed positions respectively passing and blocking flow through secondflow branch 536 and the second set of one or more nozzles 544, whichvalve opens responsive to increasing pressure of gas-liquid stream 512.Flow branch 534 provides a first stage, and one or more flow branchessuch as 536 provide second, third and so on stages, one of which isshown at 536. Respective valves 554 may open at different pressures toprovide a staggered sequentially opening multistage array providingstaggered sequentially increasing flow area. In another embodiment,valve 554, rather than on/off, may provide a variable opening variablyincreasing the size of the opening to variably increase flow areathrough second branch 536 in response to increasing pressure ofgas-liquid stream 512, including for example as in the above notedparent '603 and '688 applications. This multistage effect enables theabove noted advantages including providing increased separationefficiency early in the life of the engine without sufferingobjectionably high pressure drop late in the life of the engineincluding end-of-life condition of the engine.

Gas-liquid stream 512 flows through the first and second sets of nozzlesalong parallel flow paths 534 and 536. The noted first and secondinertial impactor collectors 540 and 546 share in one embodiment acommon impaction plate 556 at impaction zones 540 and 546 laterallyspaced along a lateral direction 558 normal to the direction of flow 560along each of the noted parallel paths. The distance 562 between thefirst set of nozzles 538 and the first inertial impactor collector 540is constant. Variable flow controller 550 is movable to control flowthrough second branch 536, and the distance 564 between the second setof one or more nozzles 544 and second inertial impactor collector 546 isconstant, including during movement of variable flow controller 550.Distance 562 is preferably equal to distance 564.

First and second side-by-side chimneys 566 and 568 are provided inhousing 528. Each chimney defines a respective axially extending flowpath therethrough, as shown at 534 and 536. First chimney 566 has afirst axial end 570 receiving gas-liquid stream 512 from housing inlet530, and has a distally opposite second axial end 572 having the firstset of one or more nozzles 538 therethrough. First chimney 566 has afirst axial flow passage 574 therethrough between first and second axialends 570 and 572, which axial flow passage 574 provides the noted firstflow branch 534. Second chimney 568 has a first axial end 576 receivinggas-liquid stream 512 from housing inlet 530, and has a distallyopposite second axial end 578 having the second set of one or morenozzles 544 therethrough. Second chimney 568 defines a second axial flowpassage 580 therethrough between the first and second axial ends 576 and578, which axial flow passage 580 provides the noted second flow branch536.

Variable flow controller 550 is axially movable in second chimney 568,FIGS. 27, 28, along axial flow passage 580. Variable flow controller 550preferably includes a valve member 554, which preferably includes a discor the like, axially movable into and out of engagement with a valveseat 582 formed in second chimney 568, to respectively close and opensecond flow branch 536, as shown in FIGS. 27 and 28, respectively. Discvalve member 554 may include an annular gasket 584, FIG. 29, forsealingly engaging valve seat 582. Valve seat 582 is at the noted firstaxial end 576 of second chimney 568. A biasing member such as helicalcompression spring 586, FIG. 29, bears between the noted second axialend 578 of second chimney 568 and valve member disc 554 and biases valvemember 554 to a normally closed position, FIG. 27, against valve seat582. Valve member 554 is axially movable upwardly in FIGS. 27, 28 to anopen position, FIG. 28, in response to pressure of gas-liquid stream 512overcoming the bias of biasing member 586. Valve member 554 in the openposition of FIG. 28 permits flow of the gas-liquid stream axially asshown at arrow 588 through second chimney 568 to the second set of oneor more nozzles 544 at the noted second axial end 578 of chimney 568.

Variable flow controller 550 is preferably an axially movable valvemember 554, as noted. Second chimney 568 has a plurality of guide trackribs 590, FIG. 31, extending axially along axial flow passage 580 andcircumferentially spaced, FIG. 30, around and disposed radiallyoutwardly of valve member 554 and guiding valve member 554, which may bea disc as above noted, for axial movement along such guide track ribs590. Chimney 568 has an axially extending inner cavity 592, FIG. 29,having an inner cavity wall 594 spaced radially outwardly of valvemember disc 554. Inner cavity wall 594 has the noted guide track ribs590 protruding radially inwardly therefrom. Guide track ribs 590 arecircumferentially spaced by arcuate gaps 596, FIG. 30, betweenrespective guide track ribs 590 and between inner cavity wall 594 andvalve member disc 554. Gas-liquid stream 512 in second flow branch 536flows axially through arcuate gaps 596.

FIG. 32 shows an inertial gas-liquid separator 600 for removing liquidparticles from a gas-liquid stream 602. The separator includes a housing604 directing the gas-liquid stream from upstream to downstreamtherethrough (left to right in FIG. 32). The housing has an inlet 606receiving the gas-liquid stream, an outlet 608 discharging a gas stream610, and a drain port 612 discharging separated liquid 614. The housinghas a housing sleeve 616 directing the gas-liquid flow axially along adownstream axial flow direction as shown at 602 against an axiallymovable plunger 618 which is biased in an upstream axial direction(leftwardly in FIG. 32) against the noted downstream axial flow.Variable nozzle orifice jet structure 620 co-acts between housing sleeve616 and plunger 618 and accelerates the gas-liquid stream radiallyoutwardly therethrough as shown at arrow 622 against an inertialimpactor collector 624 in the housing for liquid particle separation.Variable orifice jet nozzle structure 620 has a variable orifice area626 dependent upon axial movement (left-right) of plunger 618 relativeto housing sleeve 616.

Plunger 618 has a laterally spanning disk 628 facing axially upstream(leftwardly in FIG. 32) and impinged by gas-liquid stream 602 flowingaxially downstream (rightwardly in FIG. 32) through housing sleeve 616and against disk 628. The greater the pressure of gas-liquid stream 602the greater the axial downstream movement of plunger 618 against thebias thereof, supplied by biasing spring 630, and the greater thevariable orifice area 626. Plunger 618 has a plunger sleeve 632, FIG.36, extending axially upstream (leftwardly in FIGS. 32, 36) from disk628 and telescopically axially slidable along housing sleeve 616 inguided relation. Variable orifice jet nozzle structure 620 is formedalong plunger sleeve 632. Plunger sleeve 632 is axially telescopicallymovable between retracted and extended positions relative to housingsleeve 616. The extended position is in the downstream axial directionagainst the bias of biasing spring 630 and increases variable orificearea 626. Plunger sleeve 632 is provided by a circumferential sidewall634, FIG. 36, extending axially upstream from disk 628. Variable orificejet nozzle structure 620 formed along plunger sleeve 632 is provided byone or more axially elongated slots 636 extending axially along andradially through sidewall 634 and passing the gas-liquid stream radiallytherethrough as shown at arrow 622. Circumferential sidewall 634 ofplunger sleeve 632 has an upstream axial end 638. The one or moreaxially elongated slots 636 have open upstream ends 640 at upstreamaxial end 638 of circumferential sidewall 634, and have closeddownstream ends 642, FIG. 32. Housing sleeve 616 has a downstream axialend 644. The greater the downstream axial movement and extension ofplunger sleeve 632 relative to housing sleeve 616 the greater theexposed axial length of the one or more axially elongated slots 636downstream beyond the downstream axial end 644 of housing sleeve 616which are radially exposed to inertial impactor collector 624.

FIG. 33 shows another embodiment and uses like reference numerals fromabove where appropriate to facilitate understanding. Plunger 650 has aplunger sleeve 652 provided by a circumferential sidewall 654 extendingaxially upstream from plunger disk 656. The variable orifice jet nozzlestructure is formed along plunger sleeve 652 by a plurality of apertures658 through circumferential sidewall 652 and passing the gas-liquidstream radially outwardly therethrough as shown at arrow 622. Two of theapertures such as 658, 660 are at differing axial locations alongcircumferential sidewall 654. The greater the downstream axial movementand extension of plunger sleeve 652 relative to housing sleeve 616 thegreater the number of exposed apertures 660, 658, etc. beyond downstreamaxial end 644 of housing sleeve 616 which are radially exposed toinertial impactor collector 624.

FIGS. 34, 35 show another embodiment, and use like reference numeralsfrom above where appropriate to facilitate understanding. Plunger 670has a flange 672 facing upstream toward downstream axial end 644 ofhousing sleeve 616 and variably separable therefrom by a variable axialgap 674 therebetween providing the variable orifice area through whichthe gas-liquid stream flows radially outwardly as shown at arrow 622against inertial impactor collector 624. Variable axial gap 674 isdependent upon axial movement (left-right in FIG. 34) of plunger 670.Flange 672 is an outer circumferential perimeter of disk 676. Plunger670 has a downstream position with flange 672 axially spaced downstream(rightwardly in FIG. 34) from downstream axial end 644 of housing sleeve616 and with variable axial gap 674 being a continuous annulus passingthe gas-liquid stream radially therethrough as shown at arrow 622 andagainst inertial impactor collector 624. Plunger 670 has a stem 678,FIGS. 34, 35, extending axially downstream (rightwardly in FIG. 34) fromdisk 676. A bracket 680 is mounted in the housing downstream of inertialimpactor collector 624 and receives stem 678 in axially slidablerelation at sleeve 682 to guide axial movement of plunger 670.

The housing sleeve, FIGS. 32-34, includes an upstream housing sleeve asshown at 616 having a downstream axial end 644, and includes adownstream housing sleeve 684 having an inner surface having inertialimpactor collector 624 thereon and facing radially inwardly toward thenoted variable orifice jet nozzle structure. Downstream housing sleeve684 extends axially downstream (rightwardly in FIGS. 32-34) frominertial impactor collector 624 along a taper 686 providing increasedplenum volume 688. A bracket 690 in FIGS. 32, 33, 680 in FIG. 34, ismounted in the housing and provides a wall spanning the downstreamhousing sleeve 684 downstream of the inertial impactor collector and theplunger and the drain port. Opening 608 through the wall provides thenoted outlet discharging the gas stream therethrough as shown at arrow610. Drain port 612 is gravitationally below outlet 608. The separatedliquid and the gas stream flow axially downstream (rightwardly in FIGS.32-34) from inertial impactor collector 624 in the same axial directionalong downstream housing sleeve 684. Helical compression spring 630axially bears between the respective bracket 690, 680 and the plunger618, 650, 670 and biases the plunger in an upstream axial direction(leftwardly in FIGS. 32-34).

Post-impaction vortex flow separation structure 692, FIG. 36, isprovided in the housing downstream of inertial impactor collector 624and creating swirling divergent vortex flow aiding removal of separatedliquid particles. Plunger 618 has a plunger skirt 694, FIGS. 32, 36,extending axially downstream (rightwardly in FIG. 32) from the area ofliquid particle separation. Plunger skirt 694 has a plurality of angleddirectional vanes 696, FIG. 36, creating the swirling divergent vortexflow. Plunger skirt 694 and vanes 696 provide the noted post-impactionvortex flow separation structure. Downstream housing sleeve 684 isspaced radially outwardly of plunger skirt 694 by an annular space 698.Vanes 696 extend from plunger skirt 694 radially outwardly into annularspace 698. Downstream plunger skirt 694 and vanes 696 may be provided onplungers 650, 670 as shown.

FIG. 37 shows a further embodiment and uses like reference numerals fromabove where appropriate to facilitate understanding. Plunger 702 ismagnetically biased in the upstream axial direction (leftwardly in FIG.37). Bracket 704 in the housing is downstream of inertial impactorcollector 624. First and second opposing magnets 706 and 708 areprovided, with the first magnet 706 being on plunger 702, and the secondmagnet 708 being on bracket 704. Magnets 706 and 708 apply opposingrepelling magnetic force therebetween to magnetically bias plunger 702in the upstream axial direction (leftwardly in FIG. 37).

In the foregoing description, certain terms have been used for brevity,clearness, and understanding. No unnecessary limitations are to beimplied therefrom beyond the requirement of the prior art because suchterms are used for descriptive purposes and are intended to be broadlyconstrued. The different configurations, systems, and method stepsdescribed herein may be used alone or in combination with otherconfigurations, systems, and method steps. It is to be expected thatvarious equivalents, alternatives, and modifications are possible withinthe scope of the appended claims.

1-16. (canceled)
 17. An inertial gas-liquid separator for removingliquid particles from a gas-liquid stream comprising a housing having aninlet for receiving a gas-liquid stream, and an outlet for discharging agas stream, said housing having an inner cavity extending axiallybetween first and second distally opposite axial ends, said first axialend receiving said gas-liquid stream from said housing inlet, saidsecond axial end having a set of one or more nozzles accelerating saidgas-liquid stream against an inertial impactor collector in said housingfor liquid particle separation, a variable flow controller in saidhousing controlling flow between said first and second axial ends ofsaid inner cavity, said variable flow controller comprising an axiallymovable valve member.
 18. The inertial gas-liquid separator according toclaim 17 wherein said inner cavity of said housing defines an axial flowpassage between said first and second axial ends, and said housing has aplurality of guide track ribs extending axially along said axial flowpassage and circumferentially spaced around and disposed radiallyoutwardly of said valve member and guiding said valve member for axialmovement therealong.
 19. The inertial gas-liquid separator according toclaim 18 wherein said inner cavity has an inner cavity wall spacedradially outwardly of said valve member, said inner cavity wall havingsaid guide track ribs protruding radially inwardly therefrom, said guidetrack ribs being circumferentially spaced by arcuate gaps betweenrespective said guide track ribs and between said inner cavity wall andsaid valve member, wherein said gas-liquid stream flows axially throughsaid arcuate gaps.
 20. A method for separating oil from blowby gas of aninternal combustion engine, including providing increased separationefficiency early in the life of the engine without sufferingobjectionably high pressure drop late in the life of the engineincluding end-of-life condition of the engine, said method comprisingproviding an inertial air-oil separator for removing oil particles fromsaid blowby gas, providing said separator with a housing having an inletfor receiving a blowby gas stream from said engine, and an outlet fordischarging an air stream, providing first and second flow branchesthrough said housing from said inlet to said outlet, providing saidfirst flow branch with a first set of one or more nozzles receiving saidblowby gas stream from said inlet and accelerating said blowby gasstream in said first flow branch in a downstream direction through saidfirst set of one or more nozzles and against a first inertial impactorcollector in said housing in the path of said accelerated blowby gasstream through said first flow branch and causing oil particleseparation, providing said second flow branch with a second set of oneor more nozzles receiving said blowby gas stream from said inlet andaccelerating said blowby gas stream in said second flow branch in adownstream direction through said second set of one or more nozzles andagainst a second inertial impactor collector in said housing in the pathof said accelerated blowby gas stream through said second flow branchand causing oil particle separation, providing a variable flowcontroller in said second flow branch and controlling flow therethroughresponsive to pressure of said blowby gas stream, and responding toincreasing pressure of said blowby gas stream to increase flow of saidblowby gas stream through said second flow branch during the life of theengine.
 21. The method according to claim 20 comprising providing saidvariable flow controller in said second flow branch upstream of saidsecond set of one or more nozzles, and diverging said first and secondflow branches from each other at a junction downstream of said inlet andupstream of said variable flow controller.
 22. The method according toclaim 21 comprising leaving said first flow branch continuously openduring the life of the engine, continuously flowing said blowby gasstream through said first flow branch and through said first set of oneor more nozzles during the life of the engine, actuating said variableflow controller during the life of the engine to variably control flowthrough said second flow branch.
 23. The method according to claim 20comprising providing said inertial air-oil separator in one of a closedcrankcase ventilation (CCV) system and an open crankcase ventilation(OCV) system.
 24. An inertial gas-liquid separator for removing liquidparticles from a gas-liquid stream comprising a housing directing saidgas-liquid stream from upstream to downstream therethrough, said housinghaving an inlet receiving said gas-liquid stream, an outlet discharginga gas stream, and a drain port discharging separated liquid, saidhousing having a housing sleeve directing gas-liquid flow axially alonga downstream axial flow direction against an axially movable plungerwhich is biased in an upstream axial direction against said downstreamaxial flow, variable nozzle orifice jet structure co-acting between saidhousing sleeve and said plunger and accelerating said gas-liquid streamradially therethrough against an inertial impactor collector in saidhousing for liquid particle separation, said variable orifice jet nozzlestructure having a variable orifice area dependent upon axial movementof said plunger relative to said housing sleeve.
 25. The inertialgas-liquid separator according to claim 24 wherein said plunger has alaterally spanning disc facing axially upstream and impinged by saidgas-liquid stream flowing axially downstream through said housing sleeveand against said disc, the greater the pressure of said gas-liquidstream the greater the axial downstream movement of said plunger againstthe bias thereof and the greater said variable orifice area.
 26. Theinertial gas-liquid separator according to claim 25 wherein said plungerhas a plunger sleeve extending axially upstream from said disc andtelescopically axially slidable along said housing sleeve in guidedrelation, and wherein said variable orifice jet nozzle structure isformed along said plunger sleeve.
 27. The inertial gas-liquid separatoraccording to claim 26 wherein said plunger sleeve is axiallytelescopically movable between retracted and extended positions relativeto said housing sleeve, said extended position being in said downstreamaxial direction against said bias and increasing said variable orificearea.
 28. The inertial gas-liquid separator according to claim 27wherein: said plunger sleeve comprises a circumferential sidewallextending axially upstream from said disc; and said variable orifice jetnozzle structure formed along said plunger sleeve comprises one or moreaxially elongated slots extending axially along and radially throughsaid sidewall and passing said gas-liquid stream radially therethrough.29. The inertial gas-liquid separator according to claim 28 wherein saidcircumferential sidewall of said plunger sleeve has an upstream axialend, and said one or more axially elongated slots have open upstreamends at said upstream axial end of said circumferential sidewall, andhave closed downstream ends.
 30. The inertial gas-liquid separatoraccording to claim 28 wherein said housing sleeve has a downstream axialend, and wherein the greater the downstream axial movement and extensionof said plunger sleeve relative to said housing sleeve the greater theexposed axial length of said one or more axially elongated slotsdownstream beyond said downstream axial end of said housing sleeve whichare radially exposed to said inertial impactor collector.
 31. Theinertial gas-liquid separator according to claim 27 wherein said plungersleeve comprises a circumferential sidewall extending axially upstreamfrom said disc, and wherein said variable orifice jet nozzle structureformed along said plunger sleeve comprises a plurality of aperturesthrough said circumferential sidewall and passing said gas-liquid streamradially therethrough.
 32. The inertial gas-liquid separator accordingto claim 31 wherein at least two of said apertures are at differingaxial locations along said circumferential sidewall, and wherein saidhousing sleeve has a downstream axial end, and wherein the greater thedownstream axial movement and extension of said plunger sleeve relativeto said housing sleeve the greater the number of exposed said aperturesdownstream beyond said downstream axial end of said housing sleeve whichare radially exposed to said inertial impactor collector.
 33. Theinertial gas-liquid separator according to claim 25 wherein said housingsleeve has a downstream axial end, and said plunger has a flange facingupstream toward said downstream axial end of said housing sleeve andvariably separable therefrom by a variable axial gap therebetweenproviding said variable orifice area through which said gas-liquidstream flows radially against said inertial impactor collector, saidvariable axial gap being dependent upon axial movement of said plunger.34. The inertial gas-liquid separator according to claim 33 wherein saidflange is an outer circumferential perimeter of said disc.
 35. Theinertial gas-liquid separator according to claim 33 wherein said plungerhas a downstream position with said flange axially spaced downstreamfrom said downstream axial end of said housing sleeve and with saidvariable axial gap being a continuous annulus passing said gas-liquidstream radially therethrough and against said inertial impactorcollector.
 36. The inertial gas-liquid separator according to claim 33wherein said plunger has a stem extending axially downstream from saiddisc, and comprising a bracket in said housing downstream of saidinertial impactor collector and receiving said stem in axially slidablerelation to guide axial movement of said plunger.
 37. The inertialgas-liquid separator according to claim 25 wherein said housing sleevecomprises an upstream housing sleeve having a downstream axial end, andcomprising a downstream housing sleeve circumscribing said upstreamhousing sleeve at said downstream axial end thereof, said downstreamhousing sleeve having an inner surface having said inertial impactorcollector thereon and facing radially inwardly toward said variableorifice jet nozzle structure.
 38. The inertial gas-liquid separatoraccording to claim 37 wherein said downstream housing sleeve extendsaxially downstream from said inertial impactor collector along a taperproviding increased plenum volume.
 39. The inertial gas-liquid separatoraccording to claim 37 comprising a wall spanning said downstream housingsleeve downstream of said inertial impactor collector and said plungerand said drain port.
 40. The inertial gas-liquid separator according toclaim 39 comprising an opening through said wall providing said outletdischarging said gas stream therethrough.
 41. The inertial gas-liquidseparator according to claim 40 wherein said drain port isgravitationally below said outlet.
 42. The inertial gas-liquid separatoraccording to claim 39 wherein said separated liquid and said gas streamflow axially downstream from said inertial impactor collector in thesame axial direction along said downstream housing sleeve.
 43. Theinertial gas-liquid separator according to claim 37 comprising a bracketin said housing downstream of said inertial impactor collector, and ahelical compression spring axially bearing between said bracket and saidplunger and biasing said plunger in said upstream axial direction. 44.The inertial gas-liquid separator according to claim 24 wherein saidplunger is magnetically biased in said upstream axial direction.
 45. Theinertial gas-liquid separator according to claim 44 wherein said plungerhas a laterally spanning disc facing axially upstream and impinged bysaid gas-liquid stream flowing axially downstream through said housingsleeve and against said disc, the greater the pressure of saidgas-liquid stream the greater the axial downstream movement of saidplunger against the bias thereof and the greater said variable orificearea, and wherein said housing sleeve comprises an upstream housingsleeve having a downstream axial end, and comprising a downstreamhousing sleeve circumscribing said upstream housing sleeve at saiddownstream axial end thereof, said downstream housing sleeve having aninner surface having said inertial impactor collector thereon and facingradially inwardly toward said variable orifice jet nozzle structure, andcomprising a bracket in said housing downstream of said inertialimpactor collector, and comprising first and second opposing magnets,said first magnet being on said plunger, said second magnet being onsaid bracket, said first and second magnets applying opposing repellingmagnetic force therebetween to magnetically bias said plunger in saidupstream axial direction.
 46. The inertial gas-liquid separatoraccording to claim 24 comprising post-impaction vortex flow separationstructure in said housing downstream of said inertial impactor collectorand creating swirling divergent vortex flow aiding removal of saidseparated liquid particles.
 47. The inertial gas-liquid separatoraccording to claim 46 wherein said plunger has a plunger skirt extendingaxially downstream from the area of liquid particle separation, saidplunger skirt having a plurality of angled directional vanes creatingsaid swirling divergent vortex flow, said plunger skirt and said vanesproviding said post-impaction vortex flow separation structure.
 48. Theinertial gas-liquid separator according to claim 47 wherein said housingsleeve comprises an upstream housing sleeve having a downstream axialend, and comprising a downstream housing sleeve circumscribing saidupstream housing sleeve at said downstream axial end thereof, saiddownstream housing sleeve having an inner surface having said inertiaimpactor collector thereon and facing radially inwardly toward saidvariable orifice jet nozzle structure, wherein said downstream housingsleeve is spaced radially outwardly of said plunger skirt by an annularspace, and wherein said vanes extend from said plunger skirt radiallyoutwardly into said annular space.
 49. The inertial gas-liquid separatoraccording to claim 24 wherein said housing has first and second flowbranches, said first flow branch having a first set of one or morenozzles receiving said gas-liquid stream from said inlet andaccelerating said gas-liquid stream in said first flow branch in adownstream direction through said first set of one or more nozzles andagainst a first inertial impactor collector in said housing in the pathof said accelerated gas-liquid stream through said first flow branch andcausing liquid particle separation, said second flow branch having asecond set of one or more nozzles receiving said gas-liquid stream fromsaid inlet and accelerating said gas-liquid stream in said second flowbranch in a downstream direction through said second set of one or morenozzles and against a second inertial impactor collector in said housingin the path of said accelerated gas-liquid stream through said secondflow branch and causing liquid particle separation, a variable flowcontroller in said second flow branch and controlling flow therethrough,said variable flow controller being provided by said variable orificejet nozzle structure having said variable orifice area dependent uponaxial movement of said plunger relative to said housing sleeve.
 50. Aninertial impactor responsive to changing flow conditions for causing oilseparation from an oil-mist stream vented from a crankcase of an engine,comprising: a cylindrical wall having an interior surface defining anaxial flow path, the wall further defining a plurality of radiallyextending orifices, the orifices extending through the interior surfaceto an exterior surface of the wall, the radially extending orificesdefining a second flow path toward an impingement surface having aporous covering, wherein the impingement surface is spaced apart fromthe wall by an annular gap, the annular gap defining a third flow paththat is also fluidly connected to an outlet; and a variable flowcontroller that translates axially within the axial flow path to varycumulative flow by varying the number of radially extending orificesfluidly connecting the axial flow path to the gap.
 51. The inertialimpactor of claim 50, wherein at least one of the radially extendingorifices is a venturi nozzle.
 52. The inertial impactor of claim 50,wherein at least one of the radially extending orifices is afrustoconical nozzle.
 53. The inertial impactor of claim 50, wherein thevariable flow controller is a valve that opens and closes at least oneorifice.
 54. The inertial impactor of claim 53, wherein the valve is apressure relief valve.
 55. The inertial impactor of claim 54, whereinthe valve is a disc.
 56. The inertial impactor of claim 55, furthercomprising a biasing member that biases the disc to close the at leastone orifice.
 57. The inertial impactor of claim 56, wherein the biasingmember is a helical spring.
 58. The inertial impactor of claim 55,wherein the porous covering of the impactor is a fibrous covering. 59.An oil-mist inertial separator for combustion blow-by gases from acrankcase of an engine, comprising: an inlet fluidly connected to anaxial flow section within a cylinder, the cylinder including a pluralityof orifices extending radially therethrough that fluidly connect theaxial flow section to an porous fiber covered impactor collector spacedapart from the cylinder by a gap, the gap being a second flow sectionfluidly connected to the first flow section by the orifices, the gapalso being fluidly connected to an outlet; a variable flow controllerpositioned within the cylinder that moves axially to vary the totalorifice area fluidly connecting the axial flowpath to the impactor wallto be smaller in a low pressure flow condition than a higher pressureflow condition.
 60. The separator of claim 59, wherein the variable flowcontroller moves axially to maintain flow speed through the orifices atvalues that are relatively constant by varying a total cross-sectiondefined by the plurality of orifices.
 61. The separator of claim 59,wherein more orifices fluidly connect the axial flow section to theimpactor wall in the higher pressure flow condition than in the lowpressure flow condition.
 62. The separator of claim 61, wherein thevariable flow controller is a valve that opens and closes at least oneorifice.
 63. The separator of claim 62, wherein the valve is a pressurerelief valve.
 64. The separator of claim 63, wherein the valve is adisc.
 65. The separator of claim 64, further comprising a spring thatbiases the disc closed.